Article with multiple layers and method of manufacture

ABSTRACT

One general aspect of the present disclosure includes an article having a first zone, the first including a first region of a knitted base layer and a knitted second layer, where the second layer is disposed primarily on one side of the base layer. The article may further include a second zone that may include a second region of the base layer, where the second region of the base layer and the first region of the base layer have a common yarn, and where the second region of the base layer and the second layer have a common yarn. The first zone may have a first degree of elasticity such that it has a first elongation when subjected to a tensile load, and the second zone may have a second degree of elasticity such that it has a second elongation when subjected to the tensile load.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/359,108, filed Jul. 6, 2016, which is herein incorporated byreference in its entirety. This application also claims the benefit ofU.S. Provisional Application No. 62/503,704, filed May 9, 2017, which isherein incorporated by reference in its entirety.

BACKGROUND

A variety of articles are formed from textiles. As examples, articles ofapparel (e.g., shirts, pants, socks, footwear, jackets and otherouterwear, briefs and other undergarments, hats and other headwear),containers (e.g., backpacks, bags), and upholstery for furniture (e.g.,chairs, couches, car seats) are often at least partially formed fromtextiles. These textiles are often formed by weaving or interlooping(e.g., knitting) a yarn or a plurality of yarns, usually through amechanical process involving looms or knitting machines. One particularobject that may be formed from a textile is an upper for an article offootwear.

Conventional articles of footwear generally include two primaryelements: an upper and a sole structure. The upper is secured to thesole structure and forms a void within the article of footwear forcomfortably and securely receiving a foot. The sole structure is securedto a lower surface of the upper so as to be positioned between the upperand the ground. In some articles of athletic footwear, for example, thesole structure may include a midsole and an outsole. The midsole may beformed from a polymer foam material that attenuates ground reactionforces to lessen stresses upon the foot and leg during walking, running,and other ambulatory activities. The outsole may be secured to a lowersurface of the midsole and forms a ground-engaging portion of the solestructure that is formed from a durable and wear-resistant material.

The upper of the article of footwear generally extends over the instepand toe areas of the foot, along the medial and lateral sides of thefoot, and around the heel area of the foot. Access to the void on theinterior of the upper is generally provided by an ankle opening in aheel area of the footwear. A lacing system is often incorporated intothe upper to adjust the fit of the upper, thereby facilitating entry andremoval of the foot from the void within the upper. In addition, theupper may include a tongue that extends under the lacing system toenhance adjustability of the footwear, and the upper may incorporate aheel counter to limit movement of the heel.

SUMMARY

One general aspect of the present disclosure includes an article havinga first zone, the first including a first region of a knitted base layerand a knitted second layer, where the second layer is disposed primarilyon one side of the base layer. The article may further include a secondzone that may include a second region of the base layer, where thesecond region of the base layer and the first region of the base layerhave a common yarn, and where the second region of the base layer andthe second layer have a common yarn. The first zone may have a firstdegree of elasticity such that it has a first elongation when subjectedto a tensile load, and the second zone may have a second degree ofelasticity such that it has a second elongation when subjected to thetensile load. The first elongation may be at least 5% greater than thesecond elongation.

Another general aspect of the present disclosure includes an articlewith a first zone, the first zone include a knitted base layer and afirst region of a knitted second layer disposed primarily on one side ofthe base layer. The article may further include a second zone includingthe base layer and a second region of the second layer disposedprimarily on one side of the base layer, where the first zone has afirst degree of elasticity such that it has a first elongation whensubjected to a tensile load, and where the second zone has a seconddegree of elasticity such that it has a second elongation when subjectedto the tensile load. The first elongation may be at least 5% greaterthan the second elongation.

Another general aspect of the present disclosure includes a method,where the method may include the knitting a pass of a base layer with afirst yarn on a knitting machine, the knitting machine having a firstneedle bed and a second needle bed, where the base layer is at leastpartially formed on the second needle bed. The method may furtherinclude knitting at least one pass of a second layer with a second yarnat least partially on the first needle bed of the knitting machine, andtransferring the second yarn from the first needle bed to the secondneedle bed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an article of footwear in accordance with certain aspectsof the present disclosure.

FIG. 2 shows an upper for the article of footwear of FIG. 1.

FIG. 3 shows an embodiment of an article with a base layer and a secondlayer.

FIG. 4 shows an embodiment of an article with a base layer and a secondlayer having multiple structures.

FIG. 5 shows an embodiment of an article with a base layer and a secondlayer having multiple regions.

FIG. 6 shows an article with a base layer and a second layer havingtie-down yarns.

FIG. 7 shows a diagram illustrating a method of manufacturing an articlewith a base layer and a second layer.

FIG. 8 shows a diagram illustrating a method of manufacturing an articlewith a base layer and a second layer with multiple structures.

FIG. 9 shows an article with multiple zones, where a base layer hasmultiple regions having different elasticities in accordance with thepresent disclosure.

FIG. 10 shows an upper for an article of footwear incorporating certainaspect associated with the article as described with reference to FIG.9.

DETAILED DESCRIPTION

Various aspects are described below with reference to the drawings inwhich like elements generally are identified by like numerals. Therelationship and functioning of the various elements of the aspects maybetter be understood by reference to the following detailed description.However, aspects are not limited to those illustrated in the drawings orexplicitly described below. It also should be understood that thedrawings are not necessarily to scale, and in certain instances detailsmay have been omitted that are not necessary for an understanding ofaspects disclosed herein, such as conventional fabrication and assembly.

Certain aspects of the present disclosure relate to articles at leastpartially formed from textiles. One example of an article is an articleof apparel (e.g., shirts, pants, socks, footwear, jackets and otherouterwear, briefs and other undergarments, hats and other headwear, orthe like). The article may be an upper configured for use in an articleof footwear. The upper may be used in connection with any type offootwear. Illustrative, non-limiting examples of articles of footwearinclude a basketball shoe, a biking shoe, a cross-training shoe, aglobal football (soccer) shoe, an American football shoe, a bowlingshoe, a golf shoe, a hiking shoe, a ski or snowboarding boot, a tennisshoe, a running shoe, and a walking shoe. The upper may also beincorporated into a non-athletic shoe, such as a dress shoe, a loafer,and a sandal.

Referring to FIG. 1, an article of footwear 100 is generally depicted asincluding a sole 110 and an upper 120. The upper 120 includes a lateralside 104 and a medial side 105. The area of the shoe where the sole 110joins the upper 120 may be referred to as the biteline 116. The upper120 may be joined to the sole 110 in a fixed manner using any suitabletechnique, such as through the use of an adhesive, by sewing, etc. It iscontemplated that the upper 120 may extend partially or completelyaround the foot of a wearer and/or may be integral with the sole, and asockliner may or may not be used.

In some embodiments, the sole 110 includes a midsole (not shown) and anoutsole. The article of footwear 100 may additionally comprise a throat126 and an ankle opening 128, which may be surrounded by a collar 130and may lead to a void 132. The void 132 of the article of footwear 100may be configured to accommodate a foot of a person. The throat 126 isgenerally disposed in the mid-foot area 102 of the upper 120. Themid-foot area 102 is generally an area of the upper 120 located betweena heel area 101 and a toe area 103.

In some embodiments, a tongue may be disposed in the throat 126 of theshoe, but a tongue is an optional component. The tongue may be any typeof tongue, such as a gusseted tongue or a burrito tongue. If a tongue isnot included, the lateral and medial sides of the throat 126 may bejoined together. Although not shown, in some embodiments, the article offootwear 100 may include an optional fastening element, such as a lace(which may be associated with the lace apertures 136). Any suitable typeof fastening element may be used.

As depicted in FIG. 1, the upper 120 may include a base layer 140, whichis depicted herein as a textile layer, but the base layer is notnecessarily limited to textile materials. The base layer 140 may beformed of a knitted material, a woven material, one or more layers ofmesh, a solid material, and/or any other suitable material. The baselayer 140 may comprise one or more strands, threads, yarns, meshcomponents, or the like (herein referred to as a “yarn”). The base layer140 may have a first side forming an inner surface of the upper 120(e.g., facing the void 132 of the article of footwear 100) and a secondside forming an outer surface of the upper 120. In some embodiments,another object or layer, such as a cushioning layer, may be includedbetween the void and the base layer 140. The base layer 140 may beformed as an integral one-piece element. For example, the base layer 140may be formed during a single weft knitting process (e.g., with a flatknitting machine or circular knitting machine), a warp knitting process,or any other suitable knitting process such that the knitting processsubstantially forms the knit structure of the base layer 140 without theneed for significant post-knitting processes or steps. While not shown,in some embodiments, the base layer 140 of the upper 120 may beconfigured to substantially surround the foot of a wearer such that itextends beneath the plantar aspect (also known as the sole or bottom ofthe foot).

In some embodiments, the upper 120 may include a second layer 150. Whilenot limited to including a net, the second layer 150 is depicted as anet layer. Herein, a “net layer” may include, but is not limited to, anopen-meshed fabric or layer formed of yarns that are interlooped,twisted, knotted, or woven together at certain intervals, and may have arelatively low stitch density (i.e., the number of loops per measuredarea) with respect to typical knitted fabric and/or the base layer 140.In some exemplary embodiments, the second layer 150 is formed on aknitting machine. As depicted, the second layer 150 may have one or moreregions (e.g., a first region 152, a second region 154, a third region156, and a fourth region 158, shown in FIG. 2) that exhibit differentfunctional and/or visual characteristics. Each “region” of the secondlayer 150 may be associated with a “zone” of the upper 120 (i.e.,herein, a “region” refers to a layer alone, while a “zone” refers to theupper or other article). The second layer 150 may be formed as anintegral one-piece element. In some embodiments, the second layer 150and the base layer 140 are formed together as an integral one-pieceelement (which may be referred to as a “knitted component”) and may beformed by a single knitting process on a knitting machine. For example,the base layer 140 and the second layer 150 may be formed simultaneouslyand/or integrally on a multi-bed flat knitting machine.

The second layer 150 is depicted as being located on an outer surface ofthe upper 120, but it is contemplated that the second layer 150 could beat least partially located on another surface (e.g., the inner surface).Further, the second layer 150 may have substantially the same boundarydimensions as the base layer 140 such that substantially all of at leastone surface of the base layer 140 is covered by the second layer 150.Alternatively, and as depicted by FIG. 1, the second layer 150 may beabsent from an isolated region (the fifth region 142) of the base layer140. Although not shown, it is also contemplated that the article offootwear 100 may have one or more locations where the second layer 150is present but the base layer 140 is absent.

FIG. 2 shows the upper 120 of article of footwear 100 (of FIG. 1) inisolation, and potentially as the upper 120 would appear after itsformation (e.g., on a knitting machine) and before being combined withother elements of the article of footwear 100, like the sole 110. Theupper 120 may be formed as an integral one-piece element substantiallyduring a single manufacturing process (e.g., a single knitting process).

The upper 120 is shown having four zones including the second layer 150,where each zone is associated with one of the four regions 152, 154,156, and 158 of the second layer 150. The first region 152 of the secondlayer 150 may include a relatively large structure (e.g., relativelylarge cells 160 as described in more detail below). This structure mayprovide the upper 120 with a desirable level of support and elasticity,for example. The second region 154 of the second layer 150 may have arelatively dense structure (e.g., relatively small cells 160). Thisstructure may be relatively rigid and/or inelastic (at least withrespect to the first region 152), which may be advantageous in areas ofthe upper 120 where support, strength, durability, and/or otherparticular properties associated with a dense structure are desired. Insome embodiments, the first region 152 may have a first elasticity, andthe second region 154 may have a second elasticity, such that when thesame tensile load is applied to both regions, a zone with the firstregion 152 elongates at least 5% more, at least 10% more, at least 20%more, at least 50% more, or even at least 100% more (or greater) than azone with the second region 154. As shown, it may be advantageous forthe second region 154 of the second layer 150 to extend from thebiteline 116 to the throat 126 and/or to a throat area 127 adjacent tothe throat 126, which may provide durability and structural integrity toan area that commonly experiences a high degree and frequency of stressduring typical use of an article of footwear. Further, the second region154 may interact with a fastening element, such as a lace, to ensure asnug and comfortable fit of the upper 120. For example, tightening thelace may tighten the second region 154 (and its associated zone) aroundthe foot. Similarly, the third region 156, which is depicted asincluding an area of the second layer 150 with two structures (describedin more detail below), may exhibit increased strength and durability anda decreased amount of elasticity with respect to other areas and/or mayprovide a desirable visual effect. The fourth region 158 may haveanother structure (or a structure substantially the same a structurefrom another region) to achieve characteristics desired in that zone ofthe upper 120. While four regions of the second layer 150 have beenillustrated for purposes of this explanation, the second layer 150 mayhave more or less than four regions.

A fifth region 142 of the base layer 140 may include a portion of thebase layer 140 that is isolated from and uncovered by the second layer150. In this embodiment, the second layer 150 terminates at the edge ofthe fifth region 142, but it is contemplated that the structure of thesecond layer 150 could fade or otherwise slowly transition from thefourth region 158 into the fifth region 142 in a transition zone. Thefifth region 142 may elongate at least 20% more, at least 50% more, atleast 100% more, at least 200% more, or even at least 300% more (orgreater) than at least one of the zones incorporating a region of thesecond layer 150. It may be advantageous to include the fifth region 142and/or other uncovered, isolated regions of the base layer 140 whereflexibility, elasticity, and certain other characteristics that may beprimarily associated with the base layer 140 in isolation are desired.

FIG. 3 shows an article 300 with an embodiment of a second layer 350 andan underlying base layer 340. The second layer 350 may have a first yarnportion 352, a second yarn portion 354, and a third yarn portion 356,which are each depicted as extending in a serpentine pattern in asubstantially parallel direction. These yarn portions may be formed ofdifferent materials or the same material, and it is contemplated thatthey may be formed of the same continuous yarn or separate yarns. Asshown in FIG. 3, the first yarn portion 352 of the second layer 350 maybe intertwined with at least one other yarn portion, such as the secondyarn portion 354. In this embodiment, the second yarn portion 354 isintertwined with two other yarn portions: the first yarn portion 352 andthe third yarn portion 356. It is contemplated that one yarn may beintertwined with more than two yarn portions of the second layer 350. Asshown, the structure of the second layer 350 defines cells 360, whichmay have corners defined at points where the yarn portions of the secondlayer 350 are intertwined and/or overlap.

The structure of the second layer 350 may form any suitable number ofcells 360. The cells 360 are depicted in FIG. 3 as substantially beingin the shape of a quadrilateral (i.e., a four-sided polygon, such as asquare or rectangle), but it is contemplated that the second layer 350may include cells having different shapes with a different number ofsides. For example, the second layer 350 could be formed to havetriangular cells, pentagonal cells, hexagonal cells, etc. Further, thesecond layer 350 may have different regions that have a differentproperty (e.g., different cell sizes or shapes), and it is contemplatedthat the second layer 350 may have a pattern that forms cells ofdifferent shapes adjacent to one-another. The shape of the cells 360 maybe selected for certain characteristics. For example, cells having atriangular shape may have a different elasticity than quadrilateralcells at least in one direction. The size of the cells 360 may also beselected for certain properties. For example, small cells may form atighter, more rigid, and less elastic structure with respect to astructure formed by larger cells. The cells 360 may change in size inresponse to motion and/or stretching of the article 300 when the article300 is in use.

The base layer 340 and the second layer 350 may have differentfunctional and/or visual characteristics. For example, the base layer340 may be more elastic than the second layer 350. The difference inelasticity may be achieved by using yarns formed of different materialsand/or having different dimensions, by varying the way the yarnsinteract (for example, by selecting a particular knit structure thatexhibits a particular degree of elasticity), or a combination thereof.In some embodiments, the base layer 340 and the second layer 350 mayadditionally or alternatively have different degrees of strength,durability, thermal resistance, fluid (e.g., water or air) permeability,weight, flexibility, or the like. Further, the second layer 350 may havedifferent visual properties (e.g., a different color) than the baselayer 340 such that the combination of the second layer 350 and the baselayer 340 is aesthetically pleasing. It is contemplated that when thearticle 300 is in use (for example as an upper of an article offootwear), its movement may cause the second layer 350 to visibly movewith respect to the underlying base layer 340, which may create adesirable visual effect.

The yarns of the second layer 350 and the base layer 340 may be formedof any suitable material. For example, in some embodiments, the yarnsforming the second layer 350 may be formed of a material that isrelatively inelastic when compared to the yarns that form the underlyingbase layer 340. To illustrate, the yarns forming the base layer 340 mayelongate at least 5% more, at least 50% more, at least 100% more, oreven at least 500% more (and potentially greater than 500% more) thanthe yarns forming the second layer 350 when subjected to the sametensile load. The combination of the base layer 340 and the second layer350 may be advantageous for achieving a desirable combination ofcharacteristics of the article 300. For example, the base layer 340 maybe relatively soft and anti-abrasive, which are characteristics that maybe desirable for an inner surface of an upper or other articleconfigured to contact a wearer. The base layer 340 may also berelatively elastic, which when used in an upper, for example, mayfacilitate a snug and comfortable fit around the foot of the wearer. Thesecond layer 350, which may be located on an outer surface of the baselayer 340, may be relatively inelastic to provide the upper withstructural integrity and durability either throughout the entirety ofthe upper or at select locations.

FIG. 4 shows an embodiment of an article 400 where a second layer 450includes two structures, depicted as a first structure 452 and a secondstructure 454. As depicted, the first structure 452 and the secondstructure 454 each form their own cells. It is contemplated that morethan two structures may be included. The first structure 452 and thesecond structure 454 are depicted as being substantially identical, butthis is not required. In some embodiments, the first structure 452 mayhave different characteristics (either visual or functional) than thesecond structure 454. The yarns forming the first structure 452 may ormay not be interlooped with the yarns forming the second structure 454.Both of the structures may be attached to the base layer 440, butalternatively one or both of the structures may have portions that arefree from (e.g., loose with respect to) the base layer 440. The firststructure 452 may be interlocked with the second structure 454. In otherwords, when viewing the first structure 452 and the second structure 454from the viewpoint shown in FIG. 4, the first structure 452 may be infront of (e.g., closer to the viewer) the second structure 454 in somelocations, and the first structure 452 may be behind (e.g., closer tothe base layer 440) the second structure 454 in other locations. Asdepicted, the cells of the first structure 452 may be offset from thecells of the second structure 454.

FIG. 5 shows an article 500 with a second layer 550 having threedifferent regions: a first region 552, a second region 554, and a thirdregion 556. A base layer 540 may include a fourth region 542, where thefourth region 542 of the base layer 540 may be in isolation with respectto the second layer 550. Two or more of the regions of the second layer550 may have at least one different property. For example, in the firstregion 552, the second layer 550 has two structures (similar to as shownin FIG. 4). In the second region 554, the second layer 550 has a singlestructure with relatively large cells. In the third region 556, thesecond layer 550 has relatively small cells when compared to the cellsof the second region 554. The second layer 550 terminates adjacent tothe fourth region 542 of the base layer 540 such that the fourth region542 includes an uncovered and isolated portion of the base layer 540.The fourth region 542 may exhibit properties associated with the baselayer 540 alone. FIG. 5 illustrates that the article 500 can have adifferent structure, and hence different functional and/or visualproperties, in different zones. While all of the regions of the secondlayer 550 are depicted as being on the same side of the base layer 540,it is contemplated that at least one region of the second layer 550 maybe on the opposite side of the base layer 540. Further, it iscontemplated that two or more regions of the second layer 550 may bespaced apart on the base layer such that an isolated region of the baselayer 540 is disposed therebetween.

As shown in FIG. 6, an article 600 may have a second layer 650 that isattached to a base layer 640 with a series of tie-down yarns 642 at thecorners of the cells and/or a series of tie-down yarns 644 between thecorners of the cells. In some embodiments (not shown), a tie-down yarn642 may be included at substantially every corner of every cell 660, butthis is not required. The tie-down yarns 642 may be selectively placedto achieve a certain level of securement between the second layer 650and the base layer 640. It may be advantageous in some instances toprovide attachment at every corner when it is desirable for the secondlayer 650 to remain substantially in the same position with respect tothe base layer 640. In other instances, it may be advantageous to allowsome cells of the second layer 650 to remain free with respect to thebase layer 640, which may allow for varying characteristics depending onthe action of the article 600 and/or may allow for respective movementbetween the layers that produces desirable visual and/or functionaleffects. It is further contemplated that some or all of the tie-downyarns could be located at another location, such as between the cornersof the cells of the second layer 650 as shown by the tie-down yarns 644of FIG. 6.

The tie-down yarns 642 and/or 644 may be yarns that form the base layer640. For example, as described in more detail below with reference toFIGS. 7-8, the yarns 652 (of FIG. 6) that form the second layer 650 maybe integrated with (e.g., intertwined with) the yarns that form the baselayer 640 during a knitting process. It is contemplated, however, thatthe tie-down yarns 642 and/or 644 may be separate from the second layer650 and the base layer 640, and/or may be embroidered or otherwiseinstalled after the formation of the second layer 650 and the base layer640. Other forms of attachment may be additionally or alternativelyused. For example, the second layer 650 may be attached to the baselayer 640 by way of an adhesive, with a tack or mechanical clamp, bysewing, or the like.

FIG. 7 shows a diagram illustrating one method of forming an articlehaving a base layer and a second layer on a knitting machine, where theknitting machine has a first needle bed 762 and a second needle bed 764.The first needle bed 762 may be what is commonly referred to as a “frontbed” on a flat-knitting machine, and the second needle bed 764 may bewhat is commonly referred to as a “back bed” (or vice versa). Thediagram of FIG. 7 is not intended to represent the entirety of anarticle, but is shown only to illustrate one particular sequence thatmay be substantially repeated. Each repetition of the depicted sequencedoes not need to be identical. Further, FIG. 7 shows only one series ofsix (6) consecutive needles of each needle bed, and it will berecognized that the described steps may be repeated (potentially withsome alterations between repetitions) across additional needles of eachneedle bed.

Referring to FIG. 7, a first yarn 742 may be primarily associated with abase layer, and a second yarn 752 may be primarily associated with asecond layer. Step A (which is not necessarily the first step of thesequence) shows the second yarn 752 being knitted on one needle of thefirst needle bed 762 and then on a needle of the second needle bed 764being spaced about two needles apart. This spacing is not limited to two(2) needles, and it may correlate to the size of the cells of the secondlayer. Steps B-E depict knitting the first yarn 742 repeatedly on eachof the needles of the second needle bed 764. This may form the baselayer with a single jersey knit structure. In the depicted embodiment,the first yarn 742 completes four (4) passes before again knitting thesecond yarn 752. The number of consecutive passes of the base layer mayalso be associated with the cell size of the second layer. Afterknitting a portion of the base layer, the loop of the second yarn 752located on a needle of the first needle bed 762 may be transferred to aneedle of the second needle bed 764 at Step F. This may provide a pointof attachment between the second layer and the base layer (e.g., a pointwhere a tie-down yarn is located) once the knitting process iscontinued. The four depicted loops of the second yarn 752 in FIG. 7 mayeach be associated with a corner of cells of the second layer.

This sequence may be substantially repeated in Steps G-K of FIG. 7, butas depicted, the sequence of the second yarn 752 at Step G may be offsetwith respect to Step A. Here, this offset is shown as being equivalentto the distance between six (6) needles of the first needle bed 762.This offset may correspond to one dimension of the cells when theknitting process is complete. The sequence described in FIG. 7 may forman article with a structure similar to that of the article 300 of FIG.3, for example.

FIG. 8 shows a diagram illustrating one method of forming an articlehaving a base layer and a second layer with multiple structures (e.g.,as shown in FIG. 4) on a knitting machine with a first needle bed 862and a second needle bed 864. A first yarn 842 may be primarilyassociated with a base layer, and a second yarn 852 and a third yarn 854may be primarily associated with a second layer. The second yarn 852 maybe primarily associated with a first structure of the second layer, andthe third yarn 854 may be associated with a second structure of thesecond layer. In some embodiments, the second yarn 852 and the thirdyarn 854 may be substantially identical yarns, and it is contemplatedthat they may be the same continuous yarn. In the depicted Step A, thesecond yarn 852 is knitted on one needle of the first needle bed 862 andthen on a needle of the second needle bed 864 being spaced about twoneedles apart. Similarly, in Step B, the third yarn 854 is depicted asgoing through the same sequence as the second yarn 852 but being offsetby one needle. This offset may create two structures with cells that areoffset from one another (as best illustrated by FIG. 4). This offset isnot limited to one needle, and it does not necessarily need to beconstant throughout the entirety of the article.

In FIG. 8, steps C-F depict knitting the first yarn 842 repeatedly oneach of the needles of the second needle bed 864. This may form thedescribed base layer with a single jersey knit structure. After knittinga portion of the base layer, the loop of the second yarn 852 located ona needle of the first needle bed 862 may be transferred to a needle ofthe second needle bed 864 at Step G. This may form a point of attachmentbetween the base layer and the second layer. Similarly, in Step H, theloop of the third yarn 854 located on the first needle bed 862 may betransferred to the second needle bed 864.

Referring to Step I, the second yarn 852 may again be knitted on oneneedle of each of the first needle bed 862 and the second needle bed864. However, the second yarn 852 may be offset with respect to itsprevious pass. For example, it may be offset by six (6) needles withrespect to its previous pass, which may correspond with one dimension ofthe cells of the second layer. The cell size of the second layer mayalso correlate with the number of passes of the base layer alone (e.g.,the single jersey passes from Steps C-F and Steps K-N) between knittingthe second yarn 852 and/or the third yarn 854. Step J similarly involvesknitting the third yarn 854 in a manner offset from its previous pass inStep B. Steps K-N involve again knitting the first yarn 842 of the baselayer to form a single jersey structure. This knitting process may besubstantially repeated to form a multi-structure (e.g., a two structure)region.

The inventors have found that varying the structure of the second layeras described herein can achieve particular advantageous characteristics.For example, in one test, an article with five zones was formed inaccordance with the present disclosure. Herein, each zone of the articlemay be associated with a region of a second layer. One zone (e.g., theControl Zone) included only a knitted base layer without (i.e., isolatedfrom) a second layer. The 1st Zone included the base layer and a secondlayer with relatively large cells. The 2nd, 3rd, and 4th Zones includeda base layer with second layers having decreasing cell size such thatthe 4th Zone included the smallest cells. Each of the zones was formedinto an approximately 1 inch by 6 inch strip. The zones were thenseparately tested with a testing machine (i.e., an Instron 5965 TestingSystem) that applied a particular load and then measured the elongationof each of the zones at a loading speed of 50 millimeters per minute andat a gage length of 75 millimeters. Table 1 includes the data recoveredfrom these tests.

TABLE 1 Elongation at Applied Load (%) 25 N 50 N 75 N 100 N Control 1143.10 183.39 207.48 230.34 2 124.76 163.06 186.02 206.20 3 113.09150.09 170.17 185.82 Mean 126.99 165.51 187.89 207.45 SD 15.13 16.7918.73 22.29 1^(st) Zone 1 69.17 82.21 92.55 104.36 2 72.90 85.14 94.51103.87 3 66.78 78.95 89.66 99.91 Mean 69.62 82.10 92.24 102.71 SD 3.093.09 2.44 2.44 2^(nd) Zone 1 54.44 66.67 75.18 82.06 2 51.63 62.52 70.9877.76 3 51.44 62.56 70.25 76.47 Mean 52.50 63.91 72.14 78.77 SD 1.682.38 2.66 2.93 3^(rd) Zone 1 35.34 49.48 59.65 66.92 2 33.50 47.00 55.9163.59 3 33.59 47.77 56.61 64.13 Mean 34.15 48.08 57.39 64.88 SD 1.041.27 1.99 1.79 4^(th) Zone 2 16.81 24.90 30.98 36.10 3 19.18 28.56 34.7640.20 4 18.63 27.97 35.05 41.22 Mean 18.21 27.14 33.60 39.17 SD 1.241.96 2.27 2.71

As shown in Table 1, the elongation correlates with cell size, where asmaller cell size reduces the elongation. Advantageously, the cell sizeof a second layer as described herein can be selected to achieveparticular elongation properties.

In a second test, the zones were tested to determine their recoverycharacteristics. In this test, a testing machine (i.e., the Instron 5965Testing System) pulled each of the zones with a 100 Newton load for 100cycles. The gauge length was set at 100 millimeters. Displacementmeasurements were taken initially at approximately 9.8 Newtons (P₀) andthen again after the 100 cycles (P₁). Table 2 includes the datarecovered from this test. The Stretch-Recovery Index was determined bydividing the difference between the initial measured length (P₀) and thefinal measured length (P₁) by the difference between the gauge lengthand the initial length.

TABLE 2 Stretch Recovery Sample Trial P0 (mm) P1 (mm) Index (%) Control1 53.40 122.10 44.78% 2 33.45 111.00 58.11 Mean 43.43 116.55 50.981^(st) Zone 1 34.85 62.14 20.24 2 23.45 49.72 21.28 Mean 29.15 55.9320.74 2^(nd) Zone 1 13.78 34.48 18.19 2 17.42 31.59 12.07 3 16.17 36.2717.30 Mean 15.79 34.11 15.83 3^(rd) Zone 1 7.61 18.01 9.66 2 5.70 17.8111.46 3 6.32 18.21 11.19 Mean 6.54 18.01 10.77 4^(th) Zone 1 3.16 13.6810.20 2 3.66 12.07 8.12 3 4.05 11.91 7.56 Mean 3.62 12.55 8.62

As indicated by the data, the cell size of the second layer iscorrelated with a lower Stretch Recovery Index. Advantageously, thestructure of the second layer as described herein can therefore beconfigured to achieve particular recovery properties. For example, thesecond layer may provide a particular zone with a desirable lock-outeffect in certain regions of an article of footwear, for example, whileother zones may be configured to have a relatively high elasticity wherea high degree of freedom of movement is desirable.

In the embodiments above, zones with a second layer (e.g., a net layer)are generally described as having a relatively low elasticity and highstretch resistance when compared to zones without the second layer.However, it is also contemplated that zones with the net layer may berelatively elastic when compared to other zones.

For example, referring to FIG. 9, an article 900 may include a firstzone 952 and a second zone 954. The first zone 952 having a first region942 of a base layer 940 and a second layer 950, which may be similar toembodiments described above. The first region of the base layer 940 mayinclude a first yarn, and the second layer 950 may include a secondyarn. The second yarn(s) of the second layer 950 may be relativelyinelastic when compared to the first yarn(s) that forms the underlyingfirst region 942 of the base layer 940. The second layer 950 may beformed using the methods described above (e.g., by knitting the baselayer on a first needle bed while holding the second yarn on a secondneedle bed, and then transferring the second yarn to the first needlebed), and may include any of the characteristics or other aspectsdescribed above with respect to a second layer.

The second zone 954 of the article 900 may include a second region 944of the base layer 940. The second layer 950 may terminate adjacent tothe second region 944 of the base layer 940 such that it does not covera surface of the second region 944. The second region of the base layer940 may share at least one common yarn (e.g., the first yarn) and/or atleast one common course with the first region of the base layer 940, andit is contemplated that the knit structure forming the first region 942and the second region 944 may be different. The second region 944 of thebase layer 940 may also share at least one common yarn (e.g., the secondyarn) and/or at least one common course with the second layer 950located in the first region 942. In other words, the second region 944of the base layer 940 may be at least partially formed by the yarnsforming the first region 942 of the base layer 940 and the yarns formingthe second layer 950. This may, in some embodiments, result in thesecond region 944 of the base layer 940 having a higher stitch density(i.e., the total number of knit loops in a measured area of fabric) withrespect to the first region 942 of the base layer 940. Additionally, oralternatively, the second region 944 of the base layer 940 mayincorporate the second yarn (e.g., the yarn at least partially formingthe second layer 950), which may result in the second region 944 of thebase layer 940 having a different elasticity than the first region 942of the base layer 940.

As a result, the first zone 952 of the article 900 may include arelatively high elasticity when compared to the second zone 954 of thearticle in some embodiments. In other words, the first zone 952 may havea first degree of elasticity such that it has a first elongation whensubjected to a tensile load, and the second zone 954 may have a seconddegree of elasticity such that it has a second elongation when subjectedto the tensile load. The first elongation may be being at least 5% more,at least 10% more, at least 20% more, at least 50% more, or even atleast 100% more (or greater) than the second elongation, for example.

The yarns of the second region 944 of the base layer 940 may bedistributed such that the first yarns forming the first region 942 ofthe base layer 940 are primarily associated with an outer surface of thesecond region 944 and/or such that the second yarns forming the secondregion 944 of the base layer 940 are primarily associated with an innersurface of the second region 944 of the base layer 940 (or vice versa).Advantageously, from an external visual perspective, the second yarnsmay be hidden such that the first region 942 and the second region 944of the base layer 940 may have a uniform appearance, which may bedesirable aesthetically, while still exhibiting the functionalcharacteristics described above. Alternatively, the second yarns may beexposed (when associated with the outer surface) to produce a contrastin appearance between the first region 942 and the second region 944 ofthe base layer 940. Alternatively, both the first and second yarns maybe associated with both surfaces.

While not required, the article 900 may also include a third zone 956with a third region 946 of the base layer that is similar in knitstructure and/or yarn composition to the first region 942 of the baselayer 940. The second layer 950 may terminate adjacent to the thirdregion 946 of the base layer 940 such that the third region 946 of thebase layer 940 is isolated from other layers in the third zone 956. As aresult, the third zone 956 may have a relatively high elasticity whencompared to the first zone 952 and the second zone 954, and accordinglymay elongate at least 5% more, at least 10% more, at least 20% more, atleast 50% more, or even at least 100% more (or greater) than theelongation of the first zone 952 and second zone 954 when subjected to acertain tensile load. Also, while not shown, it is contemplated that thesecond layer 950 may have multiple regions (similar to as described withreference to the article 500 of FIG. 5).

Referring to FIG. 10, a knitted upper 1020 for an article of footwearmay have a first zone 1052, a second zone 1054, and a third zone 1056,which may have relative characteristics similar to those of the firstzone 952, the second zone 954, and the third zone 956 of FIG. 9. Thethree zones may be located in any suitable location of the upper 1020.As shown, for example, the first zone 1052 may extend from a biteline1016 to a throat area 1027, and may provide suitable rigidity,durability, and structural support in that particular area. The secondzone 1054 may be located in a heel area 1001, as shown, therebyproviding desirable characteristics to that area. Additionally, oralternatively, the second zone 1054 may be located in the throat area1027, which may be advantageous for providing adequate rigidity,strength, and durability where the upper 1020 is configured to couple toa fastening element (such as a lace). The third zone 1056 may be locatedin a toe region 1003 where a relatively high elasticity is desirable forproviding comfort and desirable performance of the article of footwear.The respective zones are shown in certain areas of the upper 1020 fornon-limiting illustrative purposes only, and it is contemplated that thethree zones (or more or less than three zones) could be arranged in anyparticular manner with respect to the upper 1020.

In the present disclosure, the ranges given either in absolute terms orin approximate terms are intended to encompass both, and any definitionsused herein are intended to be clarifying and not limiting.Notwithstanding that the numerical ranges and parameters setting forththe broad scope of the present embodiments are approximations, thenumerical values set forth in the specific examples are reported asprecisely as possible. Any numerical value, however, inherently containscertain errors necessarily resulting from the standard deviation foundin their respective testing measurements. Moreover, all ranges disclosedherein are to be understood to encompass any and all subranges(including all fractional and whole values) subsumed therein.

Furthermore, the present disclosure encompasses any and all possiblecombinations of some or all of the various aspects described herein. Itshould also be understood that various changes and modifications to theaspects described herein will be apparent to those skilled in the art.Such changes and modifications can be made without departing from thespirit and scope of the present disclosure and without diminishing itsintended advantages. It is therefore intended that such changes andmodifications be covered by the appended claims.

We claim:
 1. An article, the article comprising: a first zone, the firstzone including a first region of a knitted base layer and a knittedsecond layer, wherein the second layer is disposed primarily on one sideof the base layer; and a second zone including a second region of thebase layer, wherein the second region of the base layer and the firstregion of the base layer have a common yarn, and wherein the secondregion of the base layer and the second layer have a common yarn,wherein the first zone has a first degree of elasticity such that it hasa first elongation when subjected to a tensile load, and wherein thesecond zone has a second degree of elasticity such that it has a secondelongation when subjected to the tensile load, the first elongationbeing at least 5% greater than the second elongation.
 2. The article ofclaim 1, wherein the first elongation is at least 20% greater than thesecond elongation.
 3. The article of claim 1, wherein the first regionof the base layer is at least partially formed with a first yarn and thesecond layer is at least partially formed with a second yarn, the firstyarn having a characteristic different than that characteristic of thesecond yarn, wherein the first yarn is the common yarn of the first andsecond region of the base layer, and wherein the second yarn is thecommon yarn of the second layer and the second region of the base layer.4. The article of claim 3, wherein the first yarn is primarily disposedon a first side of the base layer in the second zone, and wherein thesecond yarn is primarily disposed on an opposite second side of the baselayer in the second zone.
 5. The article of claim 1, further comprisinga third zone including a third portion of the base layer, wherein thesecond layer terminates adjacent to the third portion of the base layer,and wherein the third zone includes a third elongation when subjected tothe tensile load, the third elongation being at least 5% greater thanboth the first elongation and the second elongation.
 6. The article ofclaim 1, wherein the second layer includes a first region in a firstportion of the first zone and a second region in a second portion of thefirst zone, wherein the first region has at least one property beingdifferent than the second region.
 7. The article of claim 6, wherein thefirst region of the first zone has an elongation being at least 5%greater than an elongation of the second region of the first zone whensubjected to a tensile load.
 8. The article of claim 6, wherein thefirst and second regions of the second layer are each disposed primarilyon the same side of the base layer.
 9. The article of claim 6, whereinthe first and second regions of the second layer are spaced apart on thebase layer.
 10. The article of claim 6, wherein the first region of thesecond layer includes a first structure and a second structure eachforming their own respective cells, and wherein the cells of the firststructure are offset with respect to the cells of the second structure.11. The article of claim 6, wherein the at least one property of thefirst region includes a first cell size, and wherein the at least oneproperty of the second region of the second layer includes a second cellsize, and wherein at least one dimension of the first cell size islarger than the same at least one dimension of the second cell size. 12.The article of claim 1, wherein the article is an upper for an articleof footwear, and wherein the second layer extends from a biteline of theupper to a throat area of the upper.
 13. An article comprising: a firstzone, the first zone including a knitted base layer and a first regionof a knitted second layer disposed primarily on one side of the baselayer; and a second zone, the second zone including the base layer and asecond region of the second layer disposed primarily on one side of thebase layer, wherein the first zone has a first degree of elasticity suchthat it has a first elongation when subjected to a tensile load, andwherein the second zone has a second degree of elasticity such that ithas a second elongation when subjected to the tensile load, the firstelongation being at least 5% greater than the second elongation.
 14. Thearticle of claim 13, wherein the first and second regions of the secondlayer are each disposed primarily on the same side of the base layer.15. The article of claim 13, further comprising a third zone, whereinthe base layer is isolated with respect to the second layer in the thirdzone.
 16. The article of claim 15, wherein the third zone has a thirddegree of elasticity such that it has a third elongation when subjectedto the tensile load, the third elongation being at least 20% greaterthan the second elongation.
 17. The article of claim 16, wherein the atleast one property of the first region includes a first cell size, andwherein the at least one property of the second region of the secondlayer includes a second cell size, and wherein at least one dimension ofthe first cell size is larger than the same at least one dimension ofthe second cell size.
 18. A method comprising: knitting a pass of a baselayer with a first yarn on a knitting machine, the knitting machinehaving a first needle bed and a second needle bed, wherein the baselayer is at least partially formed on the second needle bed; knitting atleast one pass of a second layer with a second yarn at least partiallyon the first needle bed of the knitting machine; and transferring thesecond yarn from the first needle bed to the second needle bed.
 19. Themethod of claim 18, wherein during the step of knitting a pass of thebase layer, the first yarn is knitted on at least two consecutiveneedles of the second needle bed, and wherein during the step ofknitting a pass of the second layer, the second yarn is knitted on aneedle of the first needle bed and on a needle of the second needle bed.20. The method of claim 19, further comprising knitting at least twopasses of the base layer on the second needle bed after the step ofknitting the pass of the second layer and before the step oftransferring the second yarn from the first needle bed to the secondneedle bed.